ESAB Warrior Feed Dual 304 Wire Feeder User manual

Brand: ESAB

Model: Warrior Feed Dual 304 Wire Feeder

Category: Welding System

Type: User manual

Warrior Feed Dual 304 Wire Feeder

Instruction Manual

0558012460 11/2015

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or

inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be

checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, dis-

torted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer rec-

ommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equip-

ment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper

repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

Be sure this information reaches the operator.

You can get extra copies through your supplier.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain

this equipment. Do NOT attempt to install or operate this equipment until you have read

and fully understand these instructions. If you do not fully understand these instructions,

contact your supplier for further information. Be sure to read the Safety Precautions be-

fore installing or operating this equipment.

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

CAUTION

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TABLE OF CONTENTS

Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize

precautionary information from the

references listed in Additional Safety

Information section. Before performing

any installation or operating procedures, be sure

to read and follow the safety precautions listed

below as well as all other manuals, material safety

data sheets, labels, etc. Failure to observe Safety

Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and can injure

skin and eyes. Hot metal can cause burns. Training

in the proper use of the processes and equipment

is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and

goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when operating

or observing operations. Warn bystanders not to

watch the arc and not to expose themselves to the

rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess trousers, high-topped shoes,

and a welding helmet or cap for hair protection, to

protect against arc rays and hot sparks or hot metal.

A ameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should

be kept buttoned, and open pockets eliminated from

the front of clothing.

5. Protect other personnel from arc rays and hot sparks

with a suitable non-ammable partition or curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective

non-ammable covering. Combustible materials

include wood, cloth, sawdust, liquid and gas fuels,

solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in oors or wall openings and cause a hid-

den smoldering re or res on the oor below. Make

certain that such openings are protected from hot

sparks and metal.“

3. Do not weld, cut or perform other hot work until the

work piece has been completely cleaned so that there

are no substances on the work piece which might

produce ammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable re extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

create a re hazard.

6. After completing operations, inspect the work area

to make certain there are no hot sparks or hot metal

which could cause a later re. Use re watchers when

necessary.

7. For additional information, refer to NFPA Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protection

Association, Battery march Park, Quincy, MA 02269.

SAFETY

1. Be sure the Power Source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. A poor

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and Power

Source.

6. Make sure that all parts of your body are insulated

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS — May be danger-

ous. Electric current owing through any conductor

causes localized Electric and Magnetic Fields (EMF).

Welding and cutting current creates EMF around

welding cables and welding machines. Therefore:

1. Welders having pacemakers should

consult their physician before weld-

ing. EMF may interfere with some

pacemakers.

2. Exposure to EMF may have other health eects

which are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of

your body.

D. Connect the work cable to the work piece as close

as possible to the area being welded.

E. Keep welding Power Source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO NOT

use AC welding current in damp areas,

if movement is conned, or if there is

danger of falling.

SAFETY

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if

mishandled, can rupture and violently

release gas. Sudden rupture of cylinder,

valve, or relief device can injure or kill.

Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

Power Source, disconnect the Power Source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and Power Source in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For more

information on safe practices for electric

arc welding and cutting equipment, ask

your supplier for a copy of "Precautions

and Safe Practices for Arc Welding, Cut-

ting and Gouging", Form 52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc

Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc

Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon

Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tung-

sten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal

Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, “Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting

and Allied Processes.

SAFETY

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or

water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and

against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not

intended to be used outside during precipitation unless sheltered.

Enclosure Class

This product is solely intended for plasma cutting. Any other use may

result in personal injury and / or equipment damage.

15°

CAUTION

If equipment is placed on a surface that slopes more

than 15°, toppling over may occur. Personal injury and

/ or signicant damage to equipment is possible.

CAUTION

To avoid personal injury and/or equipment damage,

lift using method and attachment points shown here.

CAUTION

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your

safety is involved.

WARNING

DANGER

CAUTION

Maximum Tilt

SAFETY

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description

Input Power Required ....................................................................42 V ac, 5A, 50/60 Hz, 1-phase

Wire Feed Speed Range .....................................................................75 - 950 ipm(2.0-24 m/min)

Wire Sizes Accommodated:

Hard/Soft ....................................................................... .023 thru 1/16 in. (0.6 thru 1.6 mm)

Flux Cored ......................................................................035 thru 5/64 in. (0.9 thru 2.0 mm)

Length ................................................................................................................................. 24 in. (61 cm)

Width .................................................................................................................................... 16 in. (41 cm)

Height .................................................................................................................................. 14 in. (36 cm)

Weight ................................................................................................................................. 53 lbs (24 kg)

The Warrior Feed Dual 304 Wire Feeder described in this

manual is designed for short arc, spray arc or cored wire

welding with a constant potential (CP) welding power source.

Secondary input from the power source can be DC "+" or DC "-"

depending on the requirements of the wire type being used.

The Warrior Feed Dual 304 Wire Feeder uses drive motors de-

signed to feed wires from .023 to 3/32-inches diameter. Rate

of wire feed (75 to 950 inches per minute (1.3-19 m/min)) is

precisely controlled by a solid-state, Pulse Width Modulated

(PWM) governor printed circuit board housed in the control

assembly. The Gun Switch is energized by 12 volts DC for operator safety.

The Warrior Feed Dual 304 Wire Feeder is designed to sit on at surfaces. The standard features of the Warrior Feed Dual

304 Wire Feeder include:

• 4-roll drive stands, each with two driven rolls and two pressure rolls

• 2 Internal gas solenoids

• "Euro" style torch connections and TWECO (NAS)

• Power ON/OFF switch

• Gas Purge/Jog switch

• Remote power source voltage control

• Right/Left side "Active" lights

• Cored/Solid Selection

• Independent Left/Right Voltage/Current Controls

Specications

Warrior Feed Dual 304 Wire Feeder

Table 2-1. ESAB Warrior Wire Feeder Specications

description

AMPS

MIG TORCH

CONNECTOR

RECEPTACLE

WATER OUT (WATER KIT OPTIONAL)

VOLTS

RIGHT/LEFT SIDE "ACTIVE" LIGHTS

WIRE FEED SPEED

POWER SWITCH

WIRE FEED

SPEED

CONTROL

SLOW RUN IN

ON (LEFT)

OFF (RIGHT)

2 STROKE/

4 STROKE

JOG/PURGE

VOLTAGE CONTROL

CORED/SOLID WIRE

SELECTOR SWITCH

description

Power Switch

Press this switch to turn ON or turn OFF the Wire feeder.

AMPS Display

Displays welding current and holds last value unless setting value is changed.

Wire Feed Speed Display

Displays wire feed speed and holds last value unless setting value is changed.

Volts Display

Displays preset welding voltage and holds last value unless setting value is changed.

Wire Feed Speed Control (Right and Left)

The Wire Feed Speed control knob adjusts Wire Feed Speed (WFS) (which in turn adjusts the output current by changing

the amount of MIG wire delivered to the welding arc). The optimum WFS required is dependent on the type of welding

application. The value may also be adjusted while a weld is in progress. Turn the knob either clockwise to increase WFS

or counterclockwise to decrease WFS by increments of 1.0 IPM (0.1MPM).

Voltage Control (Right and Left)

The Voltage control knob adjusts the output voltage of the power source. The welding voltage is increased by turning

the knob clockwise or decreased by turning the knob counter-clockwise. The value may also be adjusted while a weld is

in progress. Turn the knob either clockwise to increase voltage or counterclockwise to decrease voltage by increments

of 0.1V.

JOG Switch

After turning the power ON, press this switch to the left and hold it to start cold feeding. JOG is used when you need to

feed wire without welding voltage being applied. The wire is fed at the set speed for as long as the switch is energized.

PURGE Switch

This switch is used to initiate gas line purge function to ll the gas line with the shielding gas from the connected gas

cylinder. Press this switch to the right and hold it to start gas purge function. You can stop the gas purge any time by

releasing the switch. PURGE is used when measuring the gas ow or to ush any air or moisture from the gas hoses

before welding starts. Gas purging occurs for as long as the switch is held to the right and occurs without voltage or

wire feed starting.

Controls and Features

MIG Torch Connector Receptacles (Right and Left)

The MIG Torch adaptor is the connection point for the MIG welding Torch. Connect the MIG Torch by pushing the MIG

Torch connector into the brass MIG Torch adaptor rmly and tightening the plastic MIG Torch nut clockwise to secure

in position. To remove the MIG Torch simply reverse these directions.

Right/Left side "Active" lights

Illuminates to indicate which side of feeder is active.

description

4 Pin Trigger Socket (TWECO (NAS) Connection Version)

The 4 pin Trigger Socket is used to connect remote control devices to the welding power source. To make connections, align

keyway, insert plug, and rotate threaded collar fully clockwise.

Trigger Switch

Figure 3-3 4 Pin Trigger Socket

Socket Pin

Function

1 Trigger Switch Input

2 Trigger Switch Input

3 Not connected

4 Not connected

Table 3-2 Pin Function in 4 Pin Trigger Socket

Slow Run-In Switch - when activated, means that the wire is fed at low speed (1.9 m/min / 75 in/min) until it comes into

electrical contact with the workpiece, or 3 sec. has elapsed after which the speed increases to the set speed.

Solid/Cored Wire Switch

Wire selection – Solid wire

Short Circuit Termination (SCT) behavior is selected when the trigger is released to adapt to welding with solid wire.

SCT is a new way to stop the welding with some small short circuits to reduce the end crater and oxidation. It also gives

the advantage of a good start performance with solid wire.

Wire selection – Cored wire

A constant burnback time is selected when the trigger is released to adapt to welding with cored wire.

2 Stroke/4 Stroke Switch

2 stroke

With 2-stroke gas pre-ow (if used) starts when the welding torch trigger switch is pressed. The welding process then

starts. Releasing the trigger switch stops welding entirely and starts gas post-ow (if selected).

4 stroke

With 4 stroke, the gas pre-ow starts when the welding torch trigger switch is pressed in and the wire feed starts when

it is released. The welding process continues until the switch is pressed in again, the wire feed then stops and when the

switch is released the gas post-ow starts (if selected).

description

Gas Inlet

Gas inlet allows to connect the shield gas.

Welding Power Input Stud

This connector allows to connect welding cable with Wire feeder. Please make sure that it is secured rmly, or it will heat

and generate arc.

Control Cable Socket (NOTE: Connect only to an ESAB Warrior power source)

The control cable connects to the power source at this 19-pin amphenol connector. It contains the signals required to

allow the welding power source and the wire feeder to work together as a system.

5 A CIRCUIT BREAKER

CONTROL CABLE

WIRE GUIDE

REEL STAND

WELDING POWER

INPUT STUD

DOOR LATCH

WIRE SPOOL HUB

WATER IN (WATER KIT OPTIONAL)

GAS INLET

WATER KIT OPTION

The optional water kit provides a convenient way of connecting water cooled torches close to the power connection

while allowing connections to the cooler/recirculator at the rear of the unit.

description

Table 3-3 Control Cable Pin Functions

Keyway

KUNB

CPVTJ

HS RD

EFG

Figure 3-5 Pin Identication

Control Cable Pin Function

42VAC Hot

42VAC Neutral

Not Used

+24 VDC

24 VDC Common

Contactor Control

Not Used

Voltage Feedback to P/S

+15 VDC

Voltage Control REF to P/S

0 VDC

Not Used

Serial Communication V/A

Serial Communication Clock

Serial Communication Load

The protective earth ground (pin G) of the control cable is established ONLY when

the power source is properly grounded. See the power source owner’s manual for

proper grounding methods.

WARNING

description

Additional Accessories and Features

A. Constant potential Mig power source. Use with Warrior 400i and 500i power sources.

B. Shielding gas regulator/owmeter and tted hose to bring gas from owmeter to wire feeder. Such as:

Regulator/Flowmeters:

R-5007 Argon/Helium/Nitrogen, P/N 998124.

R-5008 CO

, P/N 998125.

C. Wire Reel Adapter (P/N 34323). Use with 60 or 65-lbs. (27 or 30 kg) coils.

D. Spool Spacer (P/N 34330). For adapting 10-in (25.4 cm) spools.

Optional Accessories

The following options are available from ESAB or your supplier.

• Water Kit (P/N 0465276881). Convenient way of using water cooled guns. Kit consists of inlet/outlet ttings, mount-

ing hardware and quick action connectors for the gun hoses and connecting to the Cooler/Recirculator.

NOTE:

Drive Rolls and Guide Tubes must be purchased separately to match the desired application.

Ordering Information – Accessories

Description Part Number

OKC50 Connectors female cable connector, 1/0-4/0 cable (50 mm²) 13735631 (0160361881)

OKC50 Connectors male cable connector, 1/0-4/0 cable (50 mm²) 13792513 (0160360881)

Marathon Pac Conduit QC Adaptor Kit 899F50

CONN SET 5.6 FT 19/19P 500A 0459836880

CONN SET 16.4 FT 19/19P 500A 0459836881

CONN SET 32.8 FT 19/19P 500A 0459836882

CONN SET 49.2 FT 19/19P 500A 0459836883

CONN SET 82 FT 19/19P 500A 0459836884

CONN SET 115 FT 19/19P 500A 0459836885

CONN SET 5.6 FT 19/19P 500A w/ WATER 0459836890

CONN SET 16.4 FT 19/19P 500A w/ WATER 0459836891

CONN SET 32.8 FT 19/19P 500A w/ WATER 0459836892

CONN SET 49.2 FT 19/19P 500A w/ WATER 0459836893

CONN SET 82 FT 19/19P 500A w/ WATER 0459836894

CONN SET 115 FT 19/19P 500A w/ WATER 0459836895

V350A Spray Master 15 FT Air-cooled MIG Gun (SVM315-116) 1036-1756

V450A Spray Master 15 FT Air-cooled MIG Gun (SVM415-116) 1040-1833

description

† Recommended for use with soft cored wires that are easy to atten. Order both lower drive roll and upper pressure roll.

** If a Geared Pressure Roll is desired, order P/N 23612397.

Wire Type /

Diameter

Lower

Drive

Roll

Upper

Pressure

Roll

Outlet

Guide

Tube

Center

Guide

Tube

Inlet

Guide

Tube

EURO NAS

Hard Wires (“V” groove)**

.023 in. (0.6mm) 21155 2361 2397 21163 0558008651 34612 34615

.030 in. (0.8mm) 21155 2361 2397 21164 0558008651 34612 34615

.035 in. (0.9mm) 21156 2361 2397 21165 0558008650 34612 34615

.040 in. (1.0mm) 21156 2361 2397 21165 0558008650 34612 34615

.045 in. (1.2mm) 21156 2361 2397 21165 0558008650 34612 34615

.052 in. (1.4mm) 21157 2361 2397 21166 0558008649 34612 34615

1/16 in. (1.6mm) 21157 2361 2397 21166 0558008649 34612 34615

Soft (aluminum) Wires (“U” groove)**

.030 in. (0.8mm) 21158 2361 2397 0558102450 0558102448 34612 34615

.035 in. (0.9mm) 21158 2361 2397 0558102450 0558102448 34612 34615

3/64 in. (1.2mm) 21159 2361 2397 0558102451 0558102449 34612 34615

1/16 in. (1.6mm) 21159 2361 2397 0558102451 0558102449 34612 34615

Top and Bottom Grooved- Aluminum

.035 in. (0.9mm) 36860 36860 0558102450 0558102448 34612 34615

3/64 in. (1.2mm) 36860 36860 0558102451 0558102449 34612 34615

1/16 in. (1.6mm) 36861 36861 0558102451 0558102449 34612 34615

Cored Wires (Serrated “V” groove)

.030 in. (0.8mm) 21160 2361 2369 2116 4 0558008651 34612 34615

.035 in. (0.9mm) 21160 2361 2369 21165 0558008650 34612 34615

.040 in. (1.0mm) 21161 2361 2369 21165 0558008650 34612 34615

.045 in. (1.2mm) 21161 2361 2369 21165 0558008650 34612 34615

.045 in. (1.2mm)† 37319 37319 21165 0558008650 34612 34615

.052 in. (1.4mm) 21161 2361 2369 21166 0558008649 34612 34615

.052 in. (1.4mm)† 37319 37319 2116 6 0558008649 34612 34615

1/16 in. (1.6mm) 21161 2361 2369 21166 0558008649 34612 34615

1/16 in. (1.6mm)† 37320 37320 21166 0558008649 34612 34615

5/64 in. (2.0mm) 21162 2361 2369 21166 0558008649 34613 34616

5/64 in. (2.0mm)† 37320 37320 21166 0558008649 34613 34616

Table 2.2 Drive Roll & Guide Tube Selection

installation

E. Drive Rolls. Most drive rolls have grooves for 2 wire sizes. Make sure the grooves are positioned such that they match

on both feed rolls. The groove nearest the gear motor feeds the wire. If the required groove is not correctly positioned,

perform the following:

1. Release the pressure drive roll levers and lift the assemblies upward.

2. Remove retaining screw holding each drive roll to the gear.

3. Reverse the drive roll on the drive roll shaft.

4. Replace the screws and tighten.

5. Secure the pressure drive roll assembly.

This wire feeder should NOT be earth or chassis grounded. The feeded has rubber

feet to keep it insulated. In a boom mounted arrangement, there must be an insulator

between the boom and feeder chassis. If not properly insulated and if wire touches

the chassis, such as "bird nesting", current may heat the wire and wire may contact

circuit components, causing the PC board to fail.

CAUTION

Installation

As with any work area, make sure safety glasses with side shields are worn when

handling or changing wire or clipping wire o at the spool or at the end of the torch.

Secure the wire coming o the spool with before clipping. Serious eye injury can

result due to the resilience of the wire which can quickly unravel, or a cut wire end

which may shoot across the room.

WARNING

A. Connect the 19 pin control cable to the Power Source.

B. Hose and Electrical Connections. Connect shielding gas supply hose(s). Connect secondary power cable to welding

power input stud and Power Source.

C. Attach a Mig Gun to the mating receptacles on the feeder front panel.

D. Wire Spool.

Install a spool of welding wire on the hub as follows:

1. Remove "hairpin" clip from spindle.

2. Position the spool of wire so that when it is placed on the spindle, wire will be drawn to the feed roll from the

bottom of the spool. The spool should be held so that the index hole on the back will engage the lug on the

spindle.

3. Slide the spool onto the spindle until it engages the lug. Lock in place with the hairpin clip.

4. When wire coils are to be used instead of spools, reposition the spindle to the highest position and mount wire

reel on spindle as though it were a spool (see 1 and 3 above). Remove thumbnuts and cover plate from reel.

Remove coil from its package, but do not remove its binding wires. Slide coil onto reel so that wire will be drawn

from bottom of coil (starting end for a coil is always the outer end). Replace reel cover plate and thumbnuts. Cut

o coil tie wires and any kinked wire.

installation

E. Threading Wire.

1. Turn the front panel power switch to OFF "O". Ensure control cable is disconnected from Power Source or interface

box.

2. Release pressure drive roll assembly and lift upward. Check that proper wire diameter groove is in the inner posi-

tion.

3. Feed the wire from the spool through the inlet guide, across the drive roll groove and into gun outlet guide.

Make sure that the proper "outlet guide tube" is inserted into the front panel gun tting for the size and type of

wire being used.

To ensure proper wire feeding, it is important that the wire be kept clean and that the drive rolls be periodically

cleaned of any chips or scale that might be carried into the gun liner.

4. Lower pressure roll assembly and secure. Reconnect the control cable. Turn power switch ON "I". Check that the

gears mesh. Feed wire through to gun tip using the JOG switch located on the front panel. Ensure the correct side

is active by checking the indicator light for the desired side is lit. If not lit, pull the torch trigger for the desired side

and release.

F. Brake Drag Adjustment. Brake disc friction should provide enough drag to keep the wire spool or core from spinning

freely after wire feed stops. If adjustment is required, turn adjusting screw (located inside hub) clockwise to increase

drag, counterclockwise to decrease it. Drag should be just low enough to limit wire overrun.

When the control cable is connected to power source or interface box and the power

is on, with the gun trigger depressed, the welding wire becomes electrically hot, and

the wire feed rolls are activated.

WARNING

Before threading welding wire through liner, make sure chisel point and burrs

have been removed from wire end to prevent wire from jamming in gun or liner.

CAUTION

RIGHT/LEFT SIDE "ACTIVE" LIGHTS

POWER SWITCH

oper ation

Adjustments and Operation

WARNING

Do not allow metal-to-metal contact between the wire feeder chassis and a metal

surface connected in any way to a welding ground. With such contact, a poor weld-

ing ground connection may create a dierence in potential that sends part of the

welding current through the safety ground wiring in the control cable and wire

feeder, resulting in burnout of that wiring and/or damage to wire feeder circuitry.

If the safety ground burns out, the operator may be exposed to 115 V shock hazard.

A. Selecting the "Active" side (Left/Right).

1. Apply power to wire feeder by turning on the power source and the power switch on the wire feeder front panel.

2. When power is applied to the feeder the default "Active" side is the right side (as viewed from the front of the feeder).

This should be indicated by the right "Active" pilot light being illuminated. If the desired active side is the left, mo-

mentarily depress and release the left gun trigger. The right "Active" light will extinguish and the left "Active" light

will be illuminated. The left side will remain the "Active" side until the right gun trigger is depressed. When either

gun trigger is depressed that side automatically becomes the "Active" side and the gun trigger for the opposite side

is disabled until the "Activated" gun trigger is released.

B. Control Setting.

1. Set the wire feed rate and voltage by adjusting the WIRE FEED SPEED and VOLTS control knobs on the front panel.

C. Feeding Wire. Thread wire through torch and contact tip as directed in Installation section, cut o wire so that the wire

extends approximately 1/2" (12.7 mm) beyond the end of the torch nozzle.

D. Shielding Gas Flow Rate. Operate PURGE switch and set desired gas ow rate at the shielding gas regulator-owmeter.

Activate switch for at least 15 seconds to ensure adequate purging of gas hose and torch.

E. Making the Weld. Start to weld by pressing the gun switch lever to actuate the torch switch. This closes the welding

contactor, and starts wire feed and gas ow. The trigger must be depressed for the duration of the weld. Welding action

will be stopped and all services discontinued when the lever is released and returned to its original position. If the gun

is withdrawn from the workpiece during welding, the arc will be interrupted, but shielding gas ow and welding wire

feed will continue until the trigger lever is released.

Operating Sequence

A. Normal.

1. Close torch switch.

-- Gas solenoid opens, weld contactor closes, wire feed motor runs.

2. Release torch switch.

-- Wire feed motor deenergized, brake circuit eective.

-- Burnback circuit deenergized.

3. Burnback circuit times out.

-- Weld contactor opens.

-- Gas solenoid valve closes.

oper ation

Maintenance/troubleshooting

Maintenance

Little maintenance is required to keep the wire feeder in top operating condition. It is important, however, that moving parts

such as feed and pressure rolls, wire feed motor, etc., be kept clean and free of dust or dirt. Cleaning is best accomplished

by regularly blowing o these parts with dry compressed air. This should be done once for every eight hours of operating

time, more often if necessary.

A. 42 Volt Wire Feeder and Control Circuits.

The 42-volt circuit is protected by a 5 amp circuit breaker located at the rear of the wire feeder. Failure of this circuit

breaker will shut o the contactor, shielding gas, and wire feeder.

B. Wire Feeder. As soft wire is fed, the drive rolls may pick up metal from the wire surface. Accumulation on the rolls may

score the wire with resulting unwanted friction and improper feeding.

Inspect the rolls regularly and clean them with a ne-wire power brush. Avoid roughening, or removing the hardness

of groove surfaces in grooved rolls. Any roughening may score the wire, just as the accumulation being removed may

do.

CAUTION

If this equipment does not operate properly, stop work immediately and investigate

the cause of the malfunction. Maintenance work must be performed by an experienced

person, and electrical work by a trained electrician. Do not permit untrained persons

to inspect, clean, or repair this equipment. Use only recommended replacement parts.

If it should become necessary to replace the 5 amp wire feeder circuit breaker or any

other circuit breaker/fuse in the welding machine, ensure that the proper size is used

as a replacement.

NOTE:

Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm

(11” x 17”) paper are included inside the back cover of this manual.

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ESAB Warrior Feed Dual 304 Wire Feeder User manual

Brand: ESAB

Model: Warrior Feed Dual 304 Wire Feeder

Category: Welding System

Type: User manual

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